Nissan Almera 2000 User Manual
ENGINE LUBRICATION &
COOLING SYSTEMS
CONTENTS
QG
ENGINE LUBRICATION SYSTEM..................................3
Precautions..................................................................3
LIQUID GASKET APPLICATION PROCEDURE
Preparation ..................................................................3
SPECIAL SERVICE TOOLS
Lubrication Circuit........................................................4
Oil Pressure Check......................................................5
Oil Pump......................................................................5
REMOVAL AND INSTALLATION
DISASSEMBLY AND ASSEMBLY
INSPECTION
REGULATOR VALVE INSPECTION
Changing Engine Oil....................................................8
Changing Oil Filter.......................................................9
Service Data and Specifications (SDS).....................10
OIL PRESSURE CHECK
OIL PUMP INSPECTION
REGULATOR VALVE INSPECTION
OIL CAPACITY
ENGINE COOLING SYSTEM........................................11
Precautions................................................................11
LIQUID GASKET APPLICATION PROCEDURE
Preparation ................................................................11
SPECIAL SERVICE TOOLS
Cooling Circuit ...........................................................12
System Check............................................................12
CHECKING COOLING SYSTEM HOSES
CHECKING RADIATOR
CHECKING RADIATOR CAP
CHECKING COOLING SYSTEM FOR LEAKS
Water Pump...............................................................14
REMOVAL AND INSTALLATION
INSPECTION
Thermostat.................................................................15
REMOVAL AND INSTALLATION
INSPECTION
Radiator .....................................................................17
COMPONENTS
Cooling Fan ...............................................................18
.............................................................7
........................................................10
...........................................................14
...........................................................16
.......................................................17
........................................3
.................................5
................................6
............................8
..........................................10
..........................................10
..........................10
......................................11
............................................13
....................................13
...............................14
...............................15
............3
..........11
...................12
............13
SECTION
COMPONENTS
CONTROL SYSTEM
Changing Engine Coolant..........................................18
- DRAINING ENGINE COOLANT -
- REFILLING ENGINE COOLANT -
- FLUSHING COOLING SYSTEM -
Radiator (Aluminum type)..........................................21
PREPARATION
DISASSEMBLY
ASSEMBLY
INSPECTION
Overheating Cause Analysis .....................................24
Service Data and Specifications (SDS).....................25
THERMOSTAT
RADIATOR
COOLANT CAPACITY
ENGINE LUBRICATION SYSTEM................................26
Precautions................................................................26
LIQUID GASKET APPLICATION PROCEDURE
Preparation ................................................................26
SPECIAL SERVICE TOOLS
Lubrication Circuit......................................................27
Oil Pressure Check....................................................28
Oil Pump....................................................................28
REMOVAL AND INSTALLATION
DISASSEMBLY AND ASSEMBLY
OIL PUMP INSPECTION
REGULATOR VALVE INSPECTION
Changing Engine Oil..................................................31
Oil Filter Bracket........................................................32
REMOVAL AND INSTALLATION
Changing Oil Filter.....................................................32
REMOVAL
INSTALLATION
Oil Cooler...................................................................34
REMOVAL AND INSTALLATION
Service Data and Specifications (SDS).....................35
OIL PRESSURE CHECK
.......................................................18
.......................................................21
........................................................21
.............................................................22
...........................................................23
........................................................25
..............................................................25
...............................................................33
........................................................33
LC
................................................18
............................18
...........................19
............................20
..............................................25
YD
..........26
......................................26
...............................28
..............................29
..........................................29
..........................30
...............................32
...............................34
..........................................35
CONTENTS (Cont’d)
REGULATOR VALVE INSPECTION
OIL PUMP INSPECTION
ENGINE OIL CAPACITY
..........................................35
...........................................35
..........................35
ENGINE COOLING SYSTEM........................................36
Precautions................................................................36
LIQUID GASKET APPLICATION PROCEDURE
..........36
Preparation ................................................................36
SPECIAL SERVICE TOOLS
......................................36
Cooling Circuit ...........................................................37
System Check............................................................38
CHECKING COOLING SYSTEM HOSES
CHECKING RADIATOR
CHECKING RADIATOR CAP
CHECKING COOLING SYSTEM FOR LEAKS
............................................38
....................................38
...................38
............39
Water Pump...............................................................39
REMOVAL AND INSTALLATION
REMOVAL
INSPECTION
INSTALLATION
...............................................................40
...........................................................40
........................................................40
...............................39
Thermostat.................................................................41
REMOVAL AND INSTALLATION
INSPECTION
...........................................................42
...............................41
Radiator .....................................................................42
COMPONENTS
REMOVAL AND INSTALLATION
.......................................................42
...............................43
Cooling Fan ...............................................................43
COMPONENTS
CONTROL SYSTEM
.......................................................43
................................................43
Changing Engine Coolant..........................................44
- DRAINING ENGINE COOLANT -
- REFILLING ENGINE COOLANT -
- FLUSHING COOLING SYSTEM -
............................44
...........................45
............................46
Radiator (Aluminum type)..........................................47
Overheating Cause Analysis .....................................47
Service Data and Specifications (SDS).....................48
THERMOSTAT
RADIATOR
ENGINE COOLANT CAPACITY
........................................................48
..............................................................48
................................48
LC-2
ENGINE LUBRICATION SYSTEM
Precautions
LIQUID GASKET APPLICATION PROCEDURE
1. Use a scraper to remove all traces of old liquid gasket from
mating surfaces and grooves. Also, completely clean any oil
from these areas.
2. Apply a continuous bead of liquid gasket to mating surfaces.
(Use Genuine Liquid Gasket or equivalent.)
+ For oil pan, be sure liquid gasket diameter is 3.5 to 4.5 mm
(0.138 to 0.177 in).
SEM164F
+ For areas except oil pan, be sure liquid gasket diameter is 2.0
to 3.0 mm (0.079 to 0.118 in).
3. Apply liquid gasket around the inner side of bolt holes (unless
otherwise specified).
4. Assembly should be done within 5 minutes after coating.
5. Wait at least 30 minutes before refilling engine oil and engine
coolant.
QG
Precautions
NJLC0001
Tool number
Tool name
ST25051001
Oil pressure gauge
ST25052000
Hose
KV10115801
Oil filter wrench
Description
NT050
NT559
AEM080
Preparation
SPECIAL SERVICE TOOLS
Measuring oil pressure
Adapting oil pressure gauge to cylinder block
Removing oil filter
NJLC0002
WS39930000
Tube presser
NT772
Pressing the tube of liquid gasket
NT052
LC-3
Lubrication Circuit
ENGINE LUBRICATION SYSTEM
QG
Lubrication Circuit
NJLC0003
SEM852FB
LC-4
SLC339B
ENGINELUBRICATIONSYSTEM
Oil Pressure Check
QG
SEM853F
SLC926-A
OilPressureCheck
NJLC0004
WARNING:
+ Becarefulnottoburnyourself,astheengineandoilmay
behot.
+ ForM/Tmodels,putgearshiftleverinNeutral“N”posi-
tion.ForA/Tmodels,putselectorleverinPark“P”position.
1. Checkoillevel.
2. Removeoilpressureswitch.
3. Installpressuregauge.
4. Startengineandwarmituptonormaloperatingtemperature.
5. Checkoilpressurewithenginerunningunderno-load.
ForSedan
Enginespeed
rpm
600 Morethan69(0.69,0.7,10)
2,000 Morethan284(2.84,2.9,41)
6,000 Morethan422(4.22,4.3,61)
Approximatedischargepressure
kPa(bar,kg/cm
2
,psi)
ForHatchback
Enginespeed
rpm
600 Morethan98(0.98,1.0,14)
2,000 Morethan294(2.94,3.0,43)
6,000 Morethan392(3.92,4.0,57)
Approximatedischargepressure
kPa(bar,kg/cm
2
,psi)
+ Ifdifferenceisextreme,checkoilpassageandoilpump
foroilleaks.
6. Installoilpressureswitchwithsealant.
:13-17N·m(1.25-1.75kg-m,9-12ft-lb)
OilPump
REMOVALANDINSTALLATION
+ MakesurethatO-ringisfittedproperly.
1. Drainengineoil.
2. Removedrivebelts.
3. Removeoilpan.Referto
4. Removeoilstrainer.
5. Removefrontcover.Referto
6. Installfrontcover.
7. Reinstallpartsinreverseorderofremoval.
EM-19
EM-22
, “OIL PAN”.
, “TIMING CHAIN”.
NJLC0005
LC-5
Oil Pump (Cont’d)
ENGINE LUBRICATION SYSTEM
QG
1. Oil pump cover
2. Inner rotor
3. Outer rotor
4. Front cover
DISASSEMBLY AND ASSEMBLY
5. Gasket
6. Oil strainer
7. Regulator valve
NJLC0006
SEM854FA
8. Spring
9. Washer
10. Plug
JLC307B
+ When installing oil pump, apply engine oil to rotors.
+ Install the inner rotor and outer rotor with the punched
marks on the oil pump cover side.
LC-6
ENGINE LUBRICATION SYSTEM
INSPECTION
Using a feeler gauge, check the following clearances.
Standard clearance:
For Sedan
Body to outer rotor radial clearance 1 0.114 - 0.200 (0.0045 - 0.0079)
QG
Oil Pump (Cont’d)
NJLC0007
Unit: mm (in)
SEM855F
SEM856F
Inner rotor to outer rotor tip clearance
2
Body to inner rotor clearance 3 0.030 - 0.070 (0.0012 - 0.0028)
Body to outer rotor axial clearance 4 0.030 - 0.090 (0.0012 - 0.0035)
Inner rotor to brazed portion of hous-
ing clearance 5
Below 0.18 (0.0071)
0.045 - 0.091 (0.0018 - 0.0036)
For Hatchback
Unit: mm (in)
Body to outer rotor radial clearance 1 0.250 - 0.325 (0.0098 - 0.0128)
Inner rotor to outer rotor tip clearance
2
Body to inner rotor clearance 3 0.030 - 0.085 (0.0012 - 0.0033)
Body to outer rotor axial clearance 4 0.030 - 0.090 (0.0012 - 0.0035)
Inner rotor to brazed portion of hous-
ing clearance 5
Below 0.18 (0.0071)
0.045 - 0.091 (0.0018 - 0.0036)
SEM857FA
+ If the tip clearance (2) exceeds the limit, replace rotor set.
+ If body to rotor clearances (1, 3, 4, 5) exceed the limit,
replace front cover assembly.
LC-7
Oil Pump (Cont’d)
ENGINELUBRICATIONSYSTEM
QG
SLC986AA
SLC101B
SMA915C
REGULATORVALVEINSPECTION
NJLC0008
1. Visuallyinspectcomponentsforwearanddamage.
2. Checkoilpressureregulatorvalveslidingsurfaceandvalve
spring.
3. Coatregulatorvalvewithengineoil.
Checkthatitfallssmoothlyintothevalveholebyitsown
weight.
Ifdamaged,replaceregulatorvalvesetorfrontcoverassembly.
4. Checkregulatorvalvetofrontcoverclearance.
Clearance6:
ForSedan
0.040-0.097mm(0.0016-0.0038in)
ForHatchback
0.052-0.088mm(0.0020-0.0035in)
Ifitexceedsthelimit,replacefrontcoverassembly.
ChangingEngineOil
NJLC0035
WARNING:
+ Becarefulnottoburnyourself,astheengineoilishot.
+ Prolongedandrepeatedcontactwithusedengineoilmay
causeskincancer;trytoavoiddirectskincontactwith
usedoil.Ifskincontactismade,washthoroughlywith
soaporhandcleanerassoonaspossible.
1. Warmupengine,andcheckforoilleakagefromenginecomponents.
2. Stopengineandwaitmorethan10minutes.
3. Removedrainplugandoilfillercap.
4. Drainoilandrefillwithnewengineoil.
Oilspecificationandviscosity(ExceptforEurope):
+ APIgradeSE,SF,SG,SHorSJ
+ ILSACgradeGF-I&GF-II
Oilspecificationandviscosity(ForEurope):
+ APIgradeSG,SHorSJ
+ ILSACgradeGF-I&GF-II
Referto
MA-18
, “RECOMMENDED FLUIDS AND LUBRI-
CANTS”.
Refilloilcapacity(Approximate):
Unit:!(Impqt)
Withoilfilterchange 2.7(2-3/8)
Withoutoilfilterchange 2.5(2-1/4)
Dryengine(engineoverhaul) 3.1(2-3/4)
CAUTION:
+ Besuretocleandrainplugandinstallwithnewwasher.
Drainplug:
:29-39N·m(3.0-4.0kg-m,22-29ft-lb)
+ Therefillcapacitychangesdependingontheoiltempera-
tureanddraintime,usethesevaluesasareferenceand
LC-8
ENGINE LUBRICATION SYSTEM
be certain to check with the dipstick when changing the
oil.
5. Check oil level.
6. Start engine and check area around drain plug and oil filter for
oil leakage.
7. Run engine for a few minutes, then turn it off. After several
minutes, check oil level.
QG
Changing Engine Oil (Cont’d)
SMA390C
ALC094
SLC275B
Changing Oil Filter
NJLC0010
The oil filter is a small, full-flow cartridge type and is provided with
a relief valve.
+ Use Tool KV10115801 for removing oil filter.
1. Remove oil filter with Tool.
WARNING:
Be careful not to burn yourself, as the engine and the engine
oil are hot.
2. Clean oil filter mounting surface on cylinder block. Coat rubber
seal of new oil filter with engine oil.
SMA010
LC-9
Changing Oil Filter (Cont’d)
OIL PRESSURE CHECK
Engine speed
rpm
600 More than 69 (0.69, 0.7, 10) More than 98 (0.98, 1.0, 14)
2,000 More than 284 (2.84, 2.9, 41) More than 294 (2.94, 3.0, 43)
6,000 More than 422 (4.22, 4.3, 61) More than 392 (3.92, 4.0, 57)
ENGINE LUBRICATION SYSTEM
3. Screw in the oil filter until a slight resistance is felt, then tighten
an additional 2/3 turn.
4. Add engine oil.
Refer to Changing Engine Oil.
+ Clean excess oil from engine.
SMA229B
Service Data and Specifications (SDS)
Approximate discharge pressure
kPa (bar, kg/cm
Sedan Hatchback
2
, psi)
QG
NJLC0011
OIL PUMP INSPECTION
Model Sedan Hatchback
Body to outer rotor radial clearance 0.114 - 0.200 (0.0045 - 0.0079) 0.250 - 0.325 (0.0098 - 0.0128)
Inner rotor to outer rotor tip clearance Below 0.18 (0.0071)
Body to inner rotor clearance 0.030 - 0.070 (0.0012 - 0.0028) 0.030 - 0.085 (0.0012 - 0.0033)
Body to outer rotor axial clearance 0.030 - 0.090 (0.0012 - 0.0035)
Inner rotor to brazed portion of housing clear-
ance
0.045 - 0.091 (0.0018 - 0.0036)
REGULATOR VALVE INSPECTION
Model Sedan Hatchback
Regulator valve to oil pump cover clearance 0.040 - 0.097 (0.0016 - 0.0382) 0.052 - 0.088 (0.0020 - 0.0035)
OIL CAPACITY
Unit: ! (Imp qt)
With oil filter change 2.7 (2-3/8)
Without oil filter change 2.5 (2-1/4)
Dry engine (engine overhaul) 3.1 (2-3/4)
NJLC0013
Unit: mm (in)
NJLC0012
Unit: mm (in)
NJLC0036
LC-10
ENGINE COOLING SYSTEM
Precautions
LIQUID GASKET APPLICATION PROCEDURE
1. Use a scraper to remove all traces of old liquid gasket from
mating surfaces and grooves. Also, completely clean any oil
from these areas.
2. Apply a continuous bead of liquid gasket to mating surfaces.
(Use Genuine Liquid Gasket or equivalent.)
+ For oil pan, be sure liquid gasket diameter is 3.5 to 4.5 mm
(0.138 to 0.177 in).
SEM164F
+ For areas except oil pan, be sure liquid gasket diameter is 2.0
to 3.0 mm (0.079 to 0.118 in).
3. Apply liquid gasket around the inner side of bolt holes (unless
otherwise specified).
4. Assembly should be done within 5 minutes after coating.
5. Wait at least 30 minutes before refilling engine oil and engine
coolant.
QG
Precautions
NJLC0014
Tool number
Tool name
EG17650301
Radiator cap tester
adapter
KV99103510
Radiator plate pliers A
KV99103520
Radiator plate pliers B
Description
NT564
NT224
NT225
AEM080
Preparation
SPECIAL SERVICE TOOLS
Adapting radiator cap tester to radiator filler neck
a: 28 (1.10) dia.
b: 31.4 (1.236) dia.
c: 41.3 (1.626) dia.
Unit: mm (in)
Installing radiator upper and lower tanks
Removing radiator upper and lower tanks
NJLC0015
LC-11
Cooling Circuit
ENGINE COOLING SYSTEM
QG
Cooling Circuit
NJLC0016
SLC317B
System Check
NJLC0017
WARNING:
Never remove the radiator cap when the engine is hot. Serious
burns could occur from high pressure fluid escaping from the
radiator.
Wrap a thick cloth around the cap. Slowly turn it a quarter turn
to allow built-up pressure to escape. Carefully remove the cap
by turning it all the way.
CHECKING COOLING SYSTEM HOSES
NJLC0017S01
Check hoses for the following:
+ Improper attachment
+ Leaks
+ Cracks
+ Damage
+ Loose connections
+ Chafing
+ Deterioration
LC-12
ENGINE COOLING SYSTEM
QG
System Check (Cont’d)
CHECKING RADIATOR
NJLC0017S04
Check radiator for mud or clogging. If necessary, clean radiator as
follows.
+ Be careful not to bend or damage the radiator fins.
+ When radiator is cleaned without removal, remove all sur-
rounding parts such as cooling fan, rediator shroud and horns.
Then tape the harness and connectors to prevent water from
entering.
1. Apply water by hose to the back side of the radiator core vertically download.
2. Apply water again to all radiator core surfaces once per
minute.
3. Stop washing if any stains no longer flow out from the radiator.
4. Blow air into the back side of radiator core vertically download.
+ Use compressesd air lower than 490 kPa (4.9 bar, 5 kg/cm
71 psi) and keep distance more than 30 cm (11.8 in).
5. Blow air again into all the radiator core surfaces once per
minute until no water sprays out.
CHECKING RADIATOR CAP
NJLC0017S03
To check radiator cap, apply pressure to cap with a tester.
Radiator cap relief pressure:
Standard
78-98kPa
(0.78 - 0.98 bar, 0.8 - 1.0 kg/cm
2
, 11 - 14 psi)
Limit
59-98kPa
(0.59 - 0.98 bar, 0.6 - 1.0 kg/cm
2
,9-14psi)
2
,
SLC613-A
SMA967B
SLC756AA
Pull the negative pressure valve to open it.
Check that it closes completely when released.
CHECKING COOLING SYSTEM FOR LEAKS
NJLC0017S02
To check for leakage, apply pressure to the cooling system with a
tester.
Testing pressure:
157 kPa (1.57 bar, 1.6 kg/cm
2
, 23 psi)
CAUTION:
Higher pressure than specified may cause radiator damage.
LC-13
Water Pump
ENGINE COOLING SYSTEM
Water Pump
REMOVAL AND INSTALLATION
QG
NJLC0018
SEM858F
SEM859F
CAUTION:
+ When removing water pump assembly, be careful not to
get coolant on drive belt.
+ Water pump cannot be disassembled and should be
replaced as a unit.
+ After installing water pump, and check for leaks using
radiator cap tester.
1. Drain engine coolant.
Refer to LC-18, “Changing Engine Coolant”.
2. Remove drive belts and idler pulley.
3. Loosen water pump pulley bolts.
4. Remove water pump pulley.
5. Remove front right wheel.
6. Remove front right undercover and front right fender protector.
7. Remove water pump bolts.
8. Remove water pump.
9. Reinstall parts in reverse order of removal.
INSPECTION
NJLC0019
+ Check body assembly and vane for rust or corrosion.
+ Check for rough operation due to excessive end play.
SEM860F
LC-14
ENGINE COOLING SYSTEM
Thermostat
REMOVAL AND INSTALLATION
QG
Thermostat
NJLC0021
SEM861F
SEM862F
Be careful not to spill coolant over engine compartment. Use
a rag to absorb coolant.
1. Drain engine coolant.
Refer to LC-18, “Changing Engine Coolant”.
2. Remove water inlet, then take out thermostat.
3. Install gum ring to thermostat.
4. Install thermostat with jiggle valve or air bleeder at upper side.
After installation, run engine for a few minutes, and check
for leaks.
SEM863F
LC-15
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